Non-contact Workpiece Edge Contour Measurement via Multi-angle Reflection
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Solution Overview
Problem
Existing methods for measuring the contour of workpiece edges, particularly for endless materials like steel strips, are inadequate as they require contact or reference measurements, leading to inefficiencies and unusable material due to impermissible deviations.
Innovation Solution
A non-contact method using multiple light sources arranged in a circular arc around the workpiece edge, with fixed positions and angular offsets, illuminating the edge at different angles to detect reflected light with optical sensors, allowing for precise contour determination without mechanical or optical reference measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If contact-free measurement methods are used, then measurement speed and productivity are improved, but measurement precision deteriorates due to inability to determine exact contour without reference measurements
Solution Approach 1:
The measurement process is segmented into multiple independent angular measurements taken at different incident angles. Each angle provides a separate measurement datum that, when combined with others, reconstructs the complete contour profile without requiring physical contact or reference objects.
Solution Approach 2:
The measurement approach transitions from single-angle 2D projection to multi-angle 3D contour reconstruction. By adding the angular dimension and taking measurements at multiple incident angles, the system achieves precise contour determination in three-dimensional space without contact.
2Measurement precision
If mechanical scanning methods are used, then measurement precision is improved through direct contact measurement, but productivity deteriorates due to time-consuming sequential scanning
Solution Approach 1:
Instead of sequential mechanical scanning, the system uses periodic illumination at multiple fixed angular positions. Multiple measurement points are captured simultaneously through optical means rather than sequentially through mechanical movement, dramatically improving measurement efficiency while maintaining precision.
Solution Approach 2:
The mechanical scanning system is replaced with an optical measurement system using multiple light sources at different angles. The physical contact and mechanical movement are substituted with non-contact optical detection, eliminating mechanical wear and increasing measurement speed.
3Reliability
If reference measurements are used, then measurement reliability is improved by comparing against known standards, but device complexity increases due to additional reference components
Solution Approach 1:
The measurement system uses the workpiece itself as the measurement target without requiring separate reference standards. The multi-angle optical measurement inherently provides self-referencing capability by comparing measurements across different angles, eliminating the need for external reference objects and reducing system complexity.
4Measurement precision
If multiple light sources are used at different angles, then contour determination accuracy is improved, but device complexity increases due to additional light sources and positioning
Solution Approach 1:
Multiple light sources positioned at different angular positions are merged into a single integrated measurement system. The combined illumination from multiple angles provides comprehensive contour information that cannot be obtained from a single source, improving measurement accuracy while sharing common optical detection infrastructure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables exact contour determination of workpiece edges without contact, reducing production interruptions and measurement errors, and ensuring operational reliability even in polluted environments.
Implementation Method 1
the workpiece edge is illuminated by at least one light source, so that a light beam incident on the workpiece edge in an extension in the first main direction X at an angle of incidence α with respect to the first main direction X is reflected into an associated reflected light beam
Implementation Method 2
the reflected light beams are detected by at least one optical sensor with a detection direction Y, wherein the at least one optical sensor has an imaging height H
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
The invention is therefore based on the objective of providing a solution with which any desired contour of a workpiece edge can be determined contactlessly based on the reflected light, without requiring reference measurements. This objective is achieved by a method in which the reflected light rays are detected by at least one optical sensor having an imaging height H, and the contour of the workpiece edge is calculated based on the radiation intensity of the reflected light rays detected by the optical sensor as a function of the contour-dependent exit angle β with respect to the angle of incidence α. The method according to the invention can, for example, be used for measuring cutting edges for razor blades during production.